Cushion structure



@www

R E D Y N S M H CUSHION STRUCTURE Filed Aug. 31, 1964 u o u l l n O l bn Q l n u o n D 0 n a o o o O t C n n n l n 0 o l 0 BUI anlonoote90.00600 llunaon Coulon-hu llutloc NVENTOR @my fw; awr@ United StatesPatent 3,188,665 CUSHION STRUCTURE Y Harry M. Snyder, Hickory, NAS.,assignor to Snyder Paper Corporation, Hickory, N.C., a corporation ofNorth Carolina Filed Aug. 31, 1964, Ser. No. 393,195 7 Claims. (Cl.5--355) in furniture such as sofas and overstuffed chairs or the likemust satisfy the furniture makers demand for a cushion that (l) has anattractive appearance matched to the particular style of furniture withwhich it is used; (2) has a proper feel or hand; (3) has sufficientfirmness or body to assure comfortable seating; and (4) will not loseits shape, become matted or acquire a set within the normal lifeexpectancy of the cushion.

The advent of latex foam rubber and of synthetic foam material such aspolyurethane and synthetic latex foam rubber aided cushion manufacturersin meeting these demands by providing a material which could be usedalone with a cover of ticking or the like to provide a cushion which wasreasonably soft and had a requisite amount, of firmness, and which couldbe fabricated at a cost, which, even though varying with the quality ofthe foam used in the cushion, was always substantially less than thecost of using the down traditionally found in high-quality cushions.

The use of foam as a cushion material, however, has certain drawbacks.It was found, for example, that certain furniture styles, such as EarlyAmerican, required that the cushion have a pronounced contour or crownwhich could not be easily formed with foam. In addition, it was foundthat even when layers of softer grades of foam were laminated onto arelatively firm foam base, the cushion did not have the hand found incushions made of fibrous material and demanded by the morediscriminating purchasers.

In an effort to eliminate these drawbacks, some prior art structureshave adopted a compromise arrangement which employs an open ended coverpiece or envelope comprising an outer surface of ticking and a layer offibrous material held thereagainst by an inner layer of cheesecloth orthe like sewn to the ticking, and a core piece of relatively firm foaminserted into the cover piece for enclosure thereby when the open end ofthe cover piece is sewn shut. Similarly, other prior art structures areformed by placing layers of fibrous material on opposite faces of a foamcore piece and covering these layers with pieces of ticking glued orotherwise attached to the core element. These types of cushionstructures,

however, are also difficult to form with any pronounced contour and,even more objectionalbly, the fibrous material therein tends to becomematted and disarranged after a period of use causing a deterioration inthe cushions appearance, comfort and hand.

The unique cushion structure of the present invention eliminates theabove-noted problems of the prior art and combines the desirablequalities of foam-like materials and brous materials in a compositearrangement which provides a cushion that may be employed to exceptionaladvantage in furniture seating and which can be fabricated by a simpleand inexpensive process that requires no sewing or special productionapparatus.

Brieiiy stated, the cushion structure of the present invention ischaracterized by a relatively firm base element anatre? having athickness and opposed faces proportioned in relation to the cushionstructure to be formed, a filler of fibrous material disposed at'each ofthe opposite faces of the base element, and a cover member or layer con`sisting of relatively soft open cellular elastomeric mal.

dicated generally by the reference numeral 1t) in the drawings,comprises the previously mentioned relatively firm base element 12, withfiller 14 of fibrous material disposed at each major face 16 thereof andcontained thereat by a cover member or layer 18. The base element 12 isthe core component of the cushion structure and is relied on to providethe requisite body and firmness therein. Preferably this base element 12is a relatively thick and firm block of latex foam rubber in the soft tomedium firmness range defined as 18 to 32 pounds Indentation orCompression Load Test value as measured by the standard ASTMDesignation: D105562 or The Rubber Manufacturers Association-BuyersSpecification Latex Foam. The particular firmness of the foam, thedimensions of the kopposite major faces 16, and the thickness to beemployed are dictated by the specifications for the particular cushionbeing formed. A thickness in the order of 3 to 4 inches will be suitablefor most specifications. in FIG. 2 characteristically result from themanner in which latex foam rubber is made. Although the core holes 20appearing in the FIG. 2 section all extend from the upper face of theillustrated base element 12, it will be understood that additionalbottom face core holes (not shown) are staggered therewith. One of thepreferred materials would be pin core block foam of U.S. Patent No.3,028,610. The advantage of the block foam is that filler fiber cannotwork itself into the core holes.

Although latex foam rubber is the preferred material for the baseelement 12, it can be fabricated from other open cellular elastomericmaterial, such as polyurethane foam, if a greater tendency to set andlose shape during use is acceptable in the particular cushion structurebeing formed. Alternatively, any material or combination of materialswhich provide the requisite firmness and body could be used to form thebase element 12. For example, coiled steel springs encased in a suitablecover, or rubberized horsehair are suitable materials for fabricating anadequate base element 12.

The filler 14 has a primary function of providing softf ness and hand tothe cushion structure and, in the preferred embodiment, consists of aseating grade of polyester fiber which trade standards currently defineby a weight of not less than 16 ounces per lineal yard of 32- inch lap.Suitable polyester fiber is manufactured under several trademarks, suchas Dacron, Kodel and Fortrell.

Other fibrous materials such as acetate fiber or cotton i The baseelement core holes 20 shown tions 22 extending therethrough. Thedurability andV softness of latex foam rubber make it the preferablematerial for the cover members 18 although, as in the case of the baseelement 12, other open cellular elastomeric material, such aspolyurethane, or any other material` having similar characteristicscould be used.

The preferred cushion structure is formed by first cutting a baseelement 12 of proper size from a stock of latex foam rubber having asuitable firmness and thickness of the order previously noted. The cutbase element 12 will usually have the simple shape of a substantiallyrectangular block, as illustrated in the drawings, with a length andbreadth proportioned in relation to the cushion structure to be formed.However, it may be cut as well with a corner ear portion or portions,where such shaping is desired for end sofa cushions or for chaircushions; or the shaping may be otherwise contoured in plan to suit theultimate cushion use intended.

Next, a mat of filler 14 is cut from a lap supply of seating gradepolyester ber in a size and shape allowing it to be placed on a majorbase element face 16 with a peripheral surface portion 24 of the face 16remaining exposed continuously about the ller 14 in a width of about lto 2 inches. v y

Then a pad is cut from a stock of latex foam rubber havingthe previouslynoted characteristicsl needed for the cover member 18. The shape andsize of the cut pad in plan is made to correspond with that of the baseelement 12 with suitable allowance for edge joining of the cover member18 thereto over thevfiller 14 as seen in FIG. 2. Edge joining of thecover member 18 is effected by the application of rubber cement at thecover member edges 26 and at theexposed peripheral surface portion 24 ofthe base element face 16 on which the filler 14 is disposed, and byplacing the cover member 18 over the filler 14 and turning and pressingthe edges 26 thereof on the base element peripheral portion 24-so thatthe tack of the previously applied cement secures the cushion structure10 in the form illustrated by FIG. 2 after the same procedure has beencarried out at both faces 16 of the base element 12. The rubber cementmay be one of the many commercially available soft adhesives commonlyused in the foam rubber and flexible urethane industry and may be eithera solvent based type or a latex based type. v

The edge joining of the cover members 18 induces a crowned shape theretothat is yieldably supported by the fibrous fillers 14 which are capturedand contained thereby, so that a pronounced contouring is provided atthe seating surfaces of the cushion structure 10. The degree of-thiscontouring may be altered to a considerable extent by the sizingselected for the cover members 18 in relation to the base element 12, asthe induced crowning is incushion structure 10 and must.

v would cause the cushion seating surfaces to lose shape a becomeuncomfortable, and the result is an unusually p sistent recovery of theseating surfaces to their initia formed contours after being sat upon.Additionally, t high degree of softness preferably provided in the foecover members 18 presents an appealing feel at first cc tact with thecushion seating surfaces and combines niet with the supporting fibrousfillers 14 to approximate t seating reaction of down cushioning. Becausethe cov members 18 have the perforations 22 extending ther through, theyare permitted to breathe readily so that t1 cushioning structure 10yields naturally` and comfortal: to a seating load, and it is onlynecessary to insert ti cushion structure 10 within a decorative fabriccoverii to provide furniture cushioning of extremely good quali as toboth appearance and comfort as well as durability.

This invention has been described in detail above f purposes ofillustration only and is notV intended to l limited by this descriptionor otherwise except as define n the appended'clair'ns.

I claim:

1. A composite cushion structure 'for use in furnitui comprising arelatively firm resilient base element having thickness and opposedfaces proportioned in relation 1 the cushion structure to be formed, aAfiller layer of fibrol material of substantial thickness disposed ateach of sai lopposite faces of said base element,and a relatively thicover layer consisting of a relatively soft open cellulz elastomericmaterial disposed over each of said fibror filler layers and secureddirectly and continuously to sai base element adjacent the perimeter` ofeach of said o; posite faces thereof to containv said fibrous fillerlaye thereat against disarrangement.

2. A composite cushion structure for use in furnitur comprising aresilient base element presenting oppose faces and consisting of arelativelyfirm open cellular elas tomeric material, a filler layer offibrous material of sub stantial thickness disposed at each of saidopposite basi element faces, and a relatively thin cover layer consisting of a relatively soft open cellular material disposet over eachof'said fibrous filler layers and secured directly and continuously tosaid base element adjacent the perime creased by increasing the plansize of the cover members 18 in relation to that of the base element 12and the yieldable nature of the fibrous fillers 14 allow them to adjustin thickness substantially for effectively supporting the crowned covermembers 18 despite a good deal of crowning variation.

The cushionstructure 10 provided according to the present invention isthus exceptionally well adapted for contouring to a particularappearance desired, while affording excellent hand and body firmness forcomfortable seating as well as a very advantageous durability againstloss of shape. The manner in which the fibrous fillers 14 are containedvby the cover member 18 effectively precludes any disarrangement of thefiller material that ter of each of said oppositefaces thereof tocontain saic fibrous filler layer thereat against disarrangement.

3. A composite cushion structure for use in furniture comprising aresilient base element consisting of a relatively thick and firm blockof open cellular elastomeric material having opposed major facesproportioned in relation to the cushion structure to be formed, a fillerof fibrous material disposed at each of said opposite base elementfaces, and a cover member consisting of a relatively thin and soft padof open cellular elastomeric material disposed over each of said fibrousfillers with the edge surfaces thereof secured continuously along theperimeter of the adjacent base element face to contain said fibrousfiller thereat against disarrangement.

4. yA composite cushion structure as defined in claim 3 and furthercharacterized in that said base element has a thickness in the order of3 to 4 inches and consists of latex foam rubberwithin the firmness rangeof 18 to 32 pounds compression.

5. A composite cushion structure as defined in claim 3 andfurthercharacterized in that the edge surface joining of said covermembers induces a crowned shape thereto and the fibrous filler containedthereby yieldably supports said crowned shape.

6. .A composite cushion structure as defined in claim 5 and furthercharacterized in that said fibrous filler consists of a seating grade ofpolyester fiber.

7. A composite cushion structure as defined in claim 5 and furthercharacterized in that each of said cover members has a thickness ofapproximately l/2 inch and consists of perforated Vlatex foam rubber.

(References on following page) l References Cited by the Examner UNITEDSTATES PATENTS 2,878,153 3/59 Hacklander 5-361 X 6 References Cited bythe Appcant UNITED STATES PATENTS 8/35 Gerlofson et al. 7/51 Warner.

FRANK B. SHERRY, Primary Examiner.

1. A COMPOSITE CUSHION STRUCTURE FOR TUSE IN FURNITURE COMPRISING ARELATIVELY FIRM RESILIENT BASE ELEMENT HAVING A THICKNESS AND OPPOSEDFACES PROPORTIONED IN RELATION TO THE CUSHION STRUCTURE TO BE FORMED, AFILLER LAYER OF FIBROUS MATERIAL OF SUBSTANTIAL THICKNESS DISPOSED ATEACH OF SAID OPPOSITE FACES FO SAID BASE ELEMENT, AND A RELATIVELY THINCOVER LAYER CONSISTING OF A RELATIVELY SOFT OPEN CELLULAR ELASTOMERICMATERIAL DISPOSED OVER EACH OF SAID FIBROUS FILLER LAYERS AND SECUREDDIRECTLY AND CONTINUOUSLY TO SAID BASE ELEMENT ADJACENT THE PERIMETER OFEACH OF SAID OPPOSIT FACES THEREOF TO CONTAIN SAID FIBROUS FILLER LAYERTHEREAT AGAINST DISARRANGEMENT